Process of making roofing elements



Patented June 22, 1926 UNITED STATES PATENT oFFlce.

JUTIIUS H. GIIIILIS, OE ELIZABETH, NEW JERSEY, ASSIGNOR, BY MESNEASSIGN- MENTS, TO ANACONDA. SALES COMPANY, A CORPORATION OF DELAWARE.

PROCESS OF MAKING ROOFING ELEMENTS.

Ho Drawing.

This invention relates to the manufacture of roofing elements in theform of boards, strips, shingles, tiles, and the like, andespeciallyelements which consist of a base of the type commonly used inso-called asphalt shingles having a protective metallic covering appliedto the weather surface of the ase.

Elements of the type referred to are shown and described in LettersPatent No. 1,449,058, issued March 20, 1923, to Thomas Robinson, andalso in a somewhat modified form in an application of Robinson filedFebruary 10, 1923, hearing the Ser. No. 618,246.

The ordinary asphalt shingles now in 1 general use are satisfactory formany purposes but they involve a disadvantage due to the fact that whenlaid in place on the roof and exposed to the weather they have atendency to warp or curl. Also continued exposure to the sun producesdeterioration due to the volatilization of the oils contained therein.Shingles made wholly of metal overcome the disadvantages pointed out andhave an attractive appearance, especially when made of metal such ascopper, which lends itself to the production of various 'color effects.These metal shingles, however, transmit heat with great rapidity and itis necessary to provide sheath ng which acts as a heat insulator.

The composite shingles disclosed in the Letters Patent and in theapplication com bine the several advantages of the two types, inasmuchas the metal coating adds to the life of the element by resisting wearand by preventing deterioration. vAlsothe shingle which has a metalliccoating only on its exposed or weather surface has an appearance similarin general to a solid metal shingle,

and since a comparatively thin coating is used, applied only to a ortionof the shingle surface, the cost of t ese elements is relshinglesunco'ated.

atively low and they may be handled and laid quite aseasily as theordinary asphalt In manufacturing the coated elements red ferred to thebase used is made by wellknown methods and the individual shingles arecut to the desired size and shape prior to the coating operation. Thismetallic coating is. then applied in various ways and Application filedJul as, 1923; Serial No. 653,386.

one convenient method is by electro-deposition. In the latter process itis necessary, owing to the fact that the base is an insulater, toprovide a conducting layer so that the electro-deposition may be carriedon,

process for applying a metallic coating by electro-deposition, includingthe steps inciand the present invention is directed to a ported in aconvenient manner in an electrolytic tank andthe metal deposited overthe conducting layer in the usual manner.

The application of the conducting coating involves several essentials;for instance, the adhesive used must be relatively inexpensive, must beeasily applied in a thin film and must be capable of being appliedrapidly in such a way as to completely cover the conducting surface. Ifthis film'does not cover all parts of the surface of the base over whichthe metallic layer is to be applied, the metal coating will beinterrupted and the element so formed will be imperfect and unacceptablefor use. Again, the adhesivemust be quick-drying so that this step inthe process will not consume a large amount of time, and also theadhesive must be of such a character that it will bind the conductinglayer firmly in place so that the element so treated .is capable ofstanding the handling .incidental to the electrolytic process. It isalso necessary that the adhesive should be unaflected by the electrolyteWhile the deposition is taking place, and although there are numerousadhesives which fulfill all other requirements yet if these adhesivesdissolve in the electrolyte they render the liquid impure and'in manycases result in slimes which interfere with the deposition.

'1 have found that an adhesive which fulfills all the requirementsabove, may be made bydissolving asphalt in carbon tetrachlo-- ride. Thecarbon tetrachloride used is the ordinary commercial product and asphaltis dissolved in it until there is formed a sub-- stantially saturatedsolution. Asphalt is not highly soluble in this liquid but sufiicientmay be dissolved to produce the desired adhesive material.

In treating roofing elements for the purpose of placing them incondition for the deposition of the metal, the elements as produced areconveyed to a treating tank which contains the substantially saturatedsolution of carbon tetrachloride above described, and this liquid is aplied over the surface of each element by iirushing. While. it isequally possible to use spraying or even dipping, experience hasindicated that brushing is the most satisfactory method and the workmanwill apply a thin coating of the adhesive material to that portion ofthe surface of the element upon which the metal is to be deposited. Aswill be seen later, the adhesive need not be carefully limited to theexact area which is to carry the metallic layer, but the workman willordinarily confine the adhesive coating as closely as possible to thisarea in order to save time and i also to save the adhesive.

ing the surface of theasphalt.

The coated elements are then conveyed to a heating chamber which isexhausted by suitable fans so that in drying'the carbon tetrachloridemay be recovered. The aplication of heat in this chamber not onlyhastens the evaporation but also serves to keep the residual asphalt ina tacky condition.

When this step in the process is completed the elements are conveyed toanother station where the conducting material is applied. Varioussubstances may be used for this purpose but it has been found thatowdered graphite is the most satisfactory. t is inexpensive, forms agood conductor, and the particles may be applied and spread so as toform a thin coating without abrad- For this purpose a quantity ofgraphite is placed on the shingle, sufficient to form the coating andthe graphite is then spread over the surface by soft brushes. Thisoperation can be carried on quite rapidly and it is comparatively easyto produce a thin, even, and continuous film of graphite which adheresfirmly to the tacky asphalt. While other materials, such as powderedmetal, may be applied, and will serve the purpose equally well in somerespects, it will be recalled that graphite has certain lubricatingqualities which make it preferable, inasmuch as the particles ofpowdered metal are usually sharp so that they would cut or abrade theasphalt layer during the brushing operation. I

The elements so coated are now conveyed to the electrolytic tanks andare ordinarily mounted in suitable clamps which serve to expose onlythat ortion upon which the deposition is to talie place. These clampsmay be in various forms but are made of non-condr"t ng material so thatthey re not meaess affected by the electrolyte and so that depositionwill not take place upon them, although they are beneath the surface ofthe liquid in the tanks. By using a clamp which exactly defines themetallic layer it is possible to apply the adhesive and the conductingmaterial Without paying strictattention to the limits of the area. Infact in some instances it is possible to apply the adhesive by dippingand the saving of time by such an operation will compensate for the lossof material to a great extent. The elements are left in the electrolytictroughs until a coating of the desired thickness has been depositedthereon, whereupon they are removed and, after drying, may be subjectedto a treatment for changing the color of the metal by any of thewell-known processes.

The use of carbon tetrachloride as a solvent makes it possible to useasphalt as the adhesive material, and accordingly, since the base itselfcontains asphaltic compositions, this adhesive layer, when subjected tothe heat treatment, forms a layer which is homogeneous with the base anddoes not separate from the base upon exposure of the element to theweather. The asphalt solution may, however, be applied with equallysatisfactory results to any of the well-known materials used for thebase, and since this ingredient is relatively inexpensive and the carbontetrachloride is almost completely recovered during the process it willbe seen that this step in the process involves but little expense. Thegraphite is also relatively inexpensive, inasmuch as one pound willserve to cover an area of approximately 140 to 150 square feet. Theapplication of the adhesive may be carried on by ordinary workmen, sinceno high degree of skill or attention is required.

I claim:

1. A process for the manufacture of roofing elements which comprisesapplying to the surface of a base impregnated with a waterproofingcompound a solution of the waterproofing compound in a volatile solvent,applying thereto a conducting material, and electrodepositing a metalliccoating over the conducting material.

2. A process for the manufacture of roofing elements which comprisesapplying to the surface of a base impregnated with an asphalticcompound, a solution of this compound in a volatile solvent, applyingthereto a conducting material, and electrodepositing a metallic coatingthereover.

3. A. process for the manufacture of roofing elements which comprisesapplying to a base impregnated with an asplialtic material asubstantially saturated solution of this asphaltic material in avolatile organic solvent, partially evaporating the solvent, applyin aconducting material to the base while the surface thereof is stilltacky, and carbon tetrachloride, evaporatin the carbonelectro-depositing a metallic coating theretatrachloride, applying anon-a rasiveconover. ductin material to thebase while the sur- 1 4. Apr0ces= of the manufacture of roof! face tfiereof is still tacky andelectro-de- 5 ing elements which comprises applying to positing ametallic coating thereover.

se impregnated with an asphaltm mate- In testimony whereof I aflix mysignature? rial a solution of this asphaltic material -in ULIUS HGILLIS.

